Coke oven door



Jan. 2, 1962 w. A. BOWMAN COKE OVEN DOOR Filed Sept. 50, 1959 I I'IVVEIVTOR WALTER A. BOWMAN United States Patent Ofiice 3,015,614 Patented Jan. 2, 1962 3,015,614 COKE OVEN DOOR Walter A. Bowman, Pittsburgh, Pa., assignor to United States Steel Corporation, a corporation of New Jersey Filed Sept. 30, 1959, Ser. No. 843,390 6 Claims. (Cl. 202-448) This invention relates to a coke oven door and more particularly to such a door having a refractory plug thereon. The refractory plug extends into the coke oven chamber so that it is subject to a temperature of approximately 3000 F. Since the door is removed approximately once every 24 hours and is subjected to the cooling effect of the atmosphere it is subject to a thermal shock which tends to cause it to spall and have a relatively short life. The plugs may be attached to the door frame in various Ways. Probably that in most common use is similar to that shown in Van Ackeren Patent No. 2,085,- 775 which includes steel or cast iron retainers which are bolted to the vertical sides of the door frame and which support special shape refractory sections. This type of construction is expensive because of the retainers and the special shape refractory sections. The maintenance of these type doors is also expensive because the unequal rates of expansion between the metal retainers and the refractory causes distortion of the retainers. This in turn results in cracks in the refractory which are soon filled with carbon. The carbon build-up in the cracks further distorts the retainer and sometimes results in breakage of the retainers and the bolts which hold them to the door frame. This also causes disintegration of the refractory. When the door is rebuilt it is necessary to remove all the refractory and replace it with new refractory shapes. Removal of the refractory is a tedious and expensive job. A somewhat similar type of door is shown in the Wilputte Patent No. 2,131,829 where the metal retainers along each vertical edge of the door are replaced with a vertical I-beam at the center of the door. The shortcomings of this door are much the same as that of the door shown in the Van Ackeren patent. Because the cost of construction and maintenance of the doors is high, attempts have been made to improve the door. In Potter Patent No. 2,l57,569 the door disclosed is similar to that of the Wilputte patent but'with the refractory shapes replaced with a casta-ble refractory. It has also been tried to replace the refractory shapes of the Van Ackeren door with a castable refractory. However, none of these doors with a castable refractory plug have proved satisfactory since the refractory will fail after a short period of time. Cracks form from the metal support to the outside of the plug and it is not uncommon for large pieces of the refractory to fall ofi. When this occurs there is danger of the falling piece injuring a worker. It is generally believed that the heavy metal sections are necessary in order to support the refractory, but I am of the belief that the heavy metal section is the cause of formation of the cracks. When it became necessary to rebuild these doors the refractory remaining on the door had to be removed, this being a tedious and expensive job. The refractory then had to be poured at the plant and cured in the usual manner. Thus the door was out of service for a long period of time.

It is therefore an object of my invention to provide a coke oven door in which the plug is made of a castable refractory without the use of heavy metallic supports for the castable refractory.

Another object is to provide such a door in which the plug can be preformed and readily replaced on a door frame.

Still another object is to provide such a door which is cheaper to manufacture and to rebuild than previous doors.

These and other objects will be more apparent after referring to the following specification and attached drawings, in which:

FIGURE 1 is a perspective view of the door of my invention with part of the refractory plug broken away;

FIGURE 2 is a horizontal sectional view; and

FIGURE 3 is a perspective view of the lower part of the door showing the reinforcing members.

Referring more particularly to the drawings reference numeral 2 indicates the wall of a coke oven chamber 4. A door 6 is provided for the coke oven chamber 4 and includes a conventional door frame 8 which may be constructed as in any of the patents mentioned above. Attached to the furnace side of the door frame 8 is a refractory plug 10 which is preferably made in three sections; 10a, 16b and 100. Section 10a consists of a back up plate 12 having four bolts 14 secured thereto which extend outwardly therefrom away from the chamber side. A horizontal plate 16 is welded to the bottom of plate 12 with vertical side plates 18 extending between plates l2 and 16 and being welded thereto. A generally Ushaped wire mesh reinforcement 20 is welded to the plate 12 on the oven side thereof. As shown the wire mesh 20 has parallel legs 22 perpendicular to the plate 12which are connected by a side 24 parallel to plate 12. A generally U-shaped reinforcing mesh 26 is also welded to the plate 12 and has legs 28 which converge from the plate 12 toward each other and are connected by a side 36 parallel to the plate 12. A castable refractory 32 surrounds the mesh 20 and 26 with the mesh 26 being approximately two inches beneath the surface of the refractory. It will be understood that the U-shaped members 20 and 26 may include a short portion bearing against the plate 12 as shown or these portions can extend for any length even so far as toform a complete box. The construction of the sections 1012 and is the same as the construction of section 10a except that the plates 16 and 18 are omitted. In making up the sections 10a, ltlb and 100 the steel framework is first assembled and the refractory cast therearound in a mold. The refractory is preferably a concrete mixture consisting of fire clay grog and a calcium-aluminate-hydraulic cement sold under the trademark Lumnite. The refractory is preferably a mixture consisting of one part of cement and between 2 /2 and 4 parts of crushed fire clay brick. One particular mixture found suitable includes seven standard bags of Lumnite cement, 1,100 pounds of crushed fire clay brick, sized between 8 mesh to dust and 1,100 pounds of crushed fire clay brick sized from 1 /2" to 8 mesh. After the sections 10a, 10b and 100 are formed with the concrete being cured in the usual manner they are assembled on the door frame 8 with the bolts 14 passing through openings 34 in the door frame and nuts 36 threaded on bolts 14 to hold the sections 10a, 10b and 10c in place. When assembled in the door opening the plate 16 is a slight distance above the bottom of opening 4. The purpose of the plate 16 is to protect the refractory from being sheared off. When it is necessary to replace one or more sections 16a, 1012 or 10c thenuts 36 are removed and the entire section is easily separated from the door frame 8. A new section which has been previously prepared is then positioned on the door frame 8 in the man I claim:

1. A coke oven door comprising a door frame, a plug fastened to said door frame, said plug including a generally vertical plate, a generally U-shaped member of Wire mesh extending generally vertically and having its legs fastened to said plate, a second generally U-shaped member of wire mesh extending generally vertically and having its legs fastened to said plate, the second U-shaped member being spaced from said first U-shaped member around the periphery thereof and a castable refractory surrounding said U-shaped members and abutting against said plate, and means for attaching said plate to said door frame.

2. A coke oven door according to claim 1 in which said castable refractoryis a mixture of crushed fire clay brick and a calcium aluminate hydraulic cement.

3. A coke oven door comprising a door frame, a plug fastened to said door frame, said plug being constructed of a plurality of sections arranged end to end vertically of said door, each of said sections including a generally vertical plate, a generally U-shaped member of Wire mesh extending generally vertically and having the free ends of its legs fastened to said plate, a second generally U-shaped member of wire mesh extending generally vertically and having the free ends of its-legs fastened to said plate, the second U-shaped member being spaced from said first U-shaped member around the periphery thereof and a castable refractory surrounding said U-shaped members and abutting against said plate, and means for attaching each of said plates to said door frame.

4. A coke oven door according to claim 3 in which said castable refractory is a mixture of crushed fire clay brick and a calcium aluminate hydraulic cement.

5. A coke oven door comprising 'a door frame, a plug fastened to said door frame, said plug being constructed of a plurality of sections arranged end to end vertically of said door, each of said sections including a generally vertical plate, a generally U-shaped member of wire mesh extending generally vertically and having the free ends of its legs fastened to said plate, a second generally U-shaped member of Wire mesh extending generally vertically and having the free ends of its legs fastened to said plate, the second U-shaped member being spaced from said first U-shaped member around the periphery thereof and a castable refractory surrounding said U-shaped members and abutting against said plate, and a plurality of bolts Welded to said plate and extending therefrom on the side opposite said refractory, said door frame having holes therein for receiving said bolts.

6. A coke oven door according to claim 5 in which said castable refractory is a mixture of crushed fire clay brick and a calcium aluminate hydraulic cement.

References Cited in the file of this patent UNITED STATES PATENTS 1,072,857 Kickert Sept/9, 1913 2,126,239 Beimann Aug. 9, 1938 2,251,541 Grasshofi Aug. 5, 1941 FOREIGN PATENTS 982,452 France Ian. 31, 1951 

1. A COKE OVEN DOOR COMPRISING A DOOR FRAME, A PLUG FASTENED TO SAID DOOR FRAME, SAID PLUG INCLUDING A GENERALLY VERTICAL PLATE, A GENERALLY U-SHAPED MEMBER OF WIRE MESH EXTENDING GENERALLY VERTICALLY AND HAVING ITS LEGS FASTENED TO SAID PLATE, A SECOND GENERALLY U-SHAPED MEMBER OF WIRE MESH EXTENDING GENERALLY VERTICALLY AND HAVING ITS LEGS FASTENED TO SAID PLATE, THE U-SHAPED MEMBER BEING SPACED FROM SAID FIRST U-SHAPED MEMBER AROUND THE PERIPHERY THEREOF AND A CASTABLE REFRACTORY SURROUNDING SAID U-SHAPED MEMBERS AND BUTTING AGAINST SAID PLATE, AND MEANS FOR ATTACHING SAID PLATE TO SAID DOOR FRAME. 